DC-DC converter

ABSTRACT

A DC-DC converter comprising a soft-magnetic, multi-layer substrate provided with a laminated coil constituted by connecting pluralities of conductor lines, and a semiconductor integrated circuit device comprising a switching device and a control circuit, which are mounted on the soft-magnetic, multi-layer substrate; the semiconductor integrated circuit device comprising an input terminal, an output terminal, a first control terminal for controlling the ON/OFF of the switching device, a second control terminal for variably controlling output voltage, and pluralities of ground terminals; the soft-magnetic, multi-layer substrate comprising first external terminals formed on a first main surface, first connecting wires formed on the first main surface and/or on nearby layers, second connecting wires formed between the side surface of the multi-layer substrate and a periphery of the laminated coil, and second external terminals formed on a second main surface; and terminals of the semiconductor integrated circuit device being connected to the first external terminals on the multi-layer substrate, at least part of the first external terminals being electrically connected to the second external terminals through the first and second connecting wires, and the input or output terminal being connected to the second external terminals via the laminated coil.

CROSS REFERENCE TO RELATED APPLICATIONS

This is a Continuation of application Ser. No. 12/091,601 filed Apr. 25,2008, which is a 371 of Application No. PCT/JP2006/321682 filed Oct. 30,2006, claiming the priority of JP 2005-314649 filed Oct. 28, 2005, whichare hereby incorporated by reference.

FIELD OF THE INVENTION

The present invention relates to a small DC-DC converter havingexcellent heat dissipation, with reduced magnetic flux leakage andparasitic inductance.

BACKGROUND OF THE INVENTION

Many of various mobile electronics equipments such as cell phones,mobile information terminals PDA, note PCs, mobile audio/video players,digital cameras, video cameras, etc. have DC-DC converters as devicesfor converting power source voltage to operation voltage. As one exampleof the DC-DC converter circuits, FIG. 26 shows a step-down DC-DCconverter circuit comprising an input capacitor Cin, an output capacitorCout, an output inductor Lout, and a semiconductor integrated circuit ICcomprising a control circuit CC, etc. In the step-down DC-DC converter,switching devices (for instance, field effect transistors) in thesemiconductor integrated circuit IC are switched according to a controlsignal, to lower a DC input voltage Vin to an output voltageVout[=Ton/(Ton+Toff)×Vin], wherein Ton is a time period in which theswitching devices are turned on, and Toff is a time period in which theswitching devices are turned off. The control of a Ton/Toff ratio makesit possible to stably provide a constant output voltage Vout even fromthe varying input voltage Vin.

FIG. 27 shows one example of switching circuits in the semiconductorintegrated circuit IC. A control circuit CC for controlling theswitching operation of alternately turning on and off MOS transistorsSW1, SW2 is formed on a silicon semiconductor substrate. Because thecontrol circuit CC per se is known, its explanation will be omitted. Theinput capacitor Cin stabilizes the input voltage Vin in a transientstate while preventing spike voltage, though it may be omitted. A filtercircuit (smoothing circuit) for outputting the DC voltage Vout is acombination of an output inductor Lout for storing and dischargingcurrent energy, and an output capacitor Cout for storing and dischargingvoltage energy.

To reduce the size of DC-DC converters, increasing higher switchingfrequencies have been getting used, and DC-DC converters switched at afrequency of 1 MHz are now used. Also, higher speed and function as wellas lower operation voltage and higher current have been getting used forsemiconductor devices such as CPUs, requiring that DC-DC convertersprovide lower-voltage, higher-current output. However, lower operationvoltage makes the semiconductor devices susceptible to the outputvoltage fluctuation (ripple) of the DC-DC converters. Proposed toprevent this are DC-DC converters having switching frequencies furtherincreased to about 2-10 MHz.

FIG. 28 shows one example of step-up DC-DC converter circuits. ThisDC-DC converter comprises an input inductor Lin, an output capacitorCout, and a semiconductor integrated circuit IC comprising a controlcircuit CC. By controlling time periods of turning on and off switchingdevices, a high output voltage Vout is obtained from an input voltageVin.

As another example of DC-DC converters, FIG. 29 shows a multi-phase,step-down DC-DC converter comprising an input capacitor Cin, an outputcapacitor Cout, output inductors Lout1, Lout2, and a semiconductorintegrated circuit IC comprising a control circuit CC. The multi-phaseDC-DC converter comprises pluralities of switching circuits, which areoperated with different phases lest that their switching periodsoverlap, current outputs from the switching circuits being combined by asmoothing circuit. This flows low current in each path and suppressesthe ripple.

Because such a circuit has as large an apparent operation frequency as ntimes the switching frequency, the switching frequency can be made 1/n.Accordingly, output inductors Lout1, Lout2 having excellenthigh-frequency characteristics need not be used, but high-Q-valueinductors may be used, expanding the freedom of selecting devices.Multi-phase DC-DC converters are operated with a phase difference of180° in the case of a two-phase type, and with a phase difference of120° in the case of a three-phase type. Increase in the number m ofphases increases the number of inductors, while reducing inductancenecessary for each inductor to 1/m. As a result, small inductors andhigh-Q-value inductors can be used, thereby avoiding the DC-DCconverters from becoming extremely large.

Such a DC-DC converter is generally constituted by a semiconductorintegrated circuit IC (active element) comprising switching devices anda control circuit CC, and passive elements such as an inductor and acapacitor, etc., which are mounted on a circuit board such as a printedcircuit board having connecting lines, etc. as a discrete circuit. Amongthe passive elements, an inductor that should have inductance of atleast several μH is large, occupying a large area of the circuit board,and it is not easy to reduce its size. Further, because the circuitboard should have a line pattern connecting the active element and thepassive elements, there is a limit to miniaturize the DC-DC converterconstituted as a discrete circuit.

For size reduction, the integration of a semiconductor integratedcircuit and inductors was proposed. For instance, JP 2004-063676 Adiscloses a DC-DC converter comprising a printed circuit board PB havingconnecting terminals (stud terminals) ST, a chip inductor CI connectedto the terminals ST, and a semiconductor integrated circuit IC mountedon the printed circuit board PB, the chip inductor CI and thesemiconductor integrated circuit IC being vertically overlapping (seeFIG. 30). JP 2005-124271 A discloses a DC-DC converter comprising asemiconductor integrated circuit IC and a smoothing capacitor SCdisposed on an upper surface of a glass-epoxy, multi-layer substrate MScontaining a smoothing inductor SI, the smoothing inductor SI, thesmoothing capacitor SC and the semiconductor integrated circuit IC beingconnected by wiring on the multi-layer substrate MS (see FIG. 31).

Having no wiring patterns for connecting the active elements and passiveelements, the DC-DC converters of JP 2004-063676 A and JP 2005-124271 Aneed only small mounting areas, but they suffer the following problems.

The first problem is that a chip inductor CI that should have inductanceof several μH cannot be miniaturized like a semiconductor integratedcircuit IC. Because the DC-DC converter of JP 2004-063676 A should havea slightly larger printed circuit board PB than a large chip inductorCI, it cannot be made small, but is thick due to the printed circuitboard PB and the stud terminals ST. In the DC-DC converter of JP2005-124271 A, the inductor SI generating a magnetic flux in atransverse direction of the glass-epoxy, multi-layer substrate MS shouldhave a large number of laminated coil turns to have a desired inductancebecause of a small magnetic path cross section, resulting in difficultyin its miniaturization. Also, increase in the number of laminated coilturns results in larger DC resistance, which decreases an output voltageVout. Thus, the DC-DC converter has low conversion efficiency.

The second problem is a magnetic flux leaking from an inductor. Becausethe semiconductor integrated circuit is disposed close to the inductorin the DC-DC converters of JP 2004-063676 A and JP 2005-124271 A, amagnetic flux leaking from the inductor should be reduced sufficiently.FIG. 32 shows a magnetic flux generated from a laminated inductorcomprising electric insulating layers (dummy insulating layers) and coilpatterns alternately laminated, ends of the coil patterns beingsuccessively connected to form the laminated coil, and the outermost endbeing connected to an external electrode. The magnetic flux generatedfrom the laminated coil passes through the dummy insulating layers, andpartially leaks when the dummy insulating layers are non-magnetic or notsufficiently thick. The leaked magnetic flux acts as noise to nearbyelectronic parts such as a semiconductor integrated circuit, etc. Whenthe multi-layer substrate has line patterns connecting an active elementto passive elements as in JP 2005-124271 A, the leaked magnetic fluxinduces current in the connecting patterns, thereby generating noise.

To prevent the magnetic flux leakage, the dummy insulating layer is madethicker. Also, to prevent a magnetic flux from leaking to side surfaces,the laminated coil should be provided with a smaller diameter, the dummyinsulating layer should be thicker, or the laminated coil should have alarger surrounding region. However, when the laminated coil has asmaller diameter, the number of layers for coil patterns should belarger accordingly, resulting in a thicker laminated inductor, a largernumber of steps, and larger DC resistance. A thicker dummy insulatinglayer leads to a thicker laminated inductor. Also, a larger regionaround the laminated coil makes a multi-layer substrate larger.

The third problem is the parasitic inductance. Connecting lines ofcircuit elements per se have parasitic inductance. In the step-downDC-DC converter shown in FIG. 27, for instance, parasitic inductanceseries-connected to a source of a transistor switch SW1 generates acounter electromotive force in a connecting line having parasiticinductance when the transistor switch SW1 is OFF, increasing voltage ata source terminal of the transistor switch SW1. This results in a largeturn-on loss, which leads to lower conversion efficiency. When a linepattern is formed on a printed circuit board as in JP 2004-063676 A andJP 2005-124271 A, as large inductance as to lower conversion efficiencyis not generated. But when line pattern is formed on the multi-layersubstrate 10 using a magnetic material, large parasitic inductance islikely generated.

The fourth problem is heat generated by a semiconductor integratedcircuit. Insufficient heat dissipation is likely to cause thermalrunaway in the transistor switch. Also, when a magnetic material is usedfor insulating layers constituting an inductor, the inductance varies,resulting in lower conversion efficiency.

OBJECT OF THE INVENTION

Accordingly, an object of the present invention is to provide a smallDC-DC converter having excellent heat dissipation, with reduced magneticflux leakage and parasitic inductance.

Disclosure of the Invention

The DC-DC converter of the present invention comprises a soft-magnetic,multi-layer substrate provided with a laminated coil constituted byconnecting pluralities of conductor lines, and a semiconductorintegrated circuit device comprising a switching device and a controlcircuit CC, which are mounted on the soft-magnetic, multi-layersubstrate,

the semiconductor integrated circuit device comprising an inputterminal, an output terminal, a first control terminal for controllingthe ON/OFF of the switching device, a second control terminal forvariably controlling output voltage, and pluralities of groundterminals;

the soft-magnetic, multi-layer substrate comprising first externalterminals formed on a first main surface, first connecting wires formedon the first main surface and/or on nearby layers, second connectingwires formed between the side surface of the multi-layer substrate and aperiphery of the laminated coil, and second external terminals formed ona second main surface; and

terminals of the semiconductor integrated circuit device being connectedto the first external terminals on the multi-layer substrate, at leastpart of the first external terminals being electrically connected to thesecond external terminals through the first and second connecting wires,and the input or output terminal being connected to the second externalterminals via the laminated coil.

The multi-layer substrate preferably has an overcoat glass on an outersurface, and an insulating layer therein.

The DC-DC converter may be a multi-phase type in which the semiconductorintegrated circuit device has pluralities of output terminals, to whichone ends of different laminated coils are connected, and the other endsof the laminated coils are connected to second common externalterminals. To reduce magnetic coupling between pluralities of laminatedcoils, pluralities of laminated coils are preferably arranged in ahorizontal direction inside the multi-layer substrate, with adjacentcoils having different winding directions.

The semiconductor integrated circuit device may have a negative feedbackterminal, the first external terminal connected to the negative feedbackterminal being connected to the other end of the laminated coilconnected to the output terminal. The negative feedback terminal may beconnected to the other end of the laminated coil via a resistor. Theresistor may be a chip resistor, or a resistor printed on themulti-layer substrate.

Capacitance elements constituting a filter circuit (smoothing circuit)for preventing spike voltage and outputting DC voltage are preferablymounted to the first external terminals formed on the first main surfaceof the multi-layer substrate, and the input and/or output terminals ofthe semiconductor integrated circuit device are preferably grounded. Themounting of capacitance elements to the multi-layer substrate can reducethe area of the DC-DC converter circuit occupying a circuit board. Also,the mounting of capacitance elements can reduce influence of parasiticinductance generated by the first and second connecting wires, etc.

The multi-layer substrate preferably comprises first common connectingwires to which pluralities of ground terminals of the semiconductorintegrated circuit device are connected, the first common connectingwires being connected to the second external terminals via pluralitiesof second connecting wires. Such structure reduces parasitic inductancebetween the semiconductor integrated circuit device and the ground, andefficiently lets heat generated by the semiconductor integrated circuitdevice escape.

The second connecting wires are preferably conductor strips formed onthe side surface of the multi-layer substrate. Such structure reducesparasitic inductance more than when the second connecting wires areformed in the multi-layer substrate. The multi-layer substrate may havecastellation (recesses) from the first main surface to the second mainsurface, and second connecting wires formed by conductor strips or sidevia-holes on the bottom. This enables the reduction of parasiticinductance and the mounting of other devices near the side surface ofthe multi-layer substrate, thereby increasing the mounting density ofdevices on a circuit board.

The second connecting wires can be formed by via-holes passing throughpluralities of layers in a thickness direction. Although the formationof via-holes in the multi-layer substrate provides large parasiticinductance, it increases the density of devices mounted on a circuitboard. To reduce the parasitic inductance, at least part of via-holesmay be exposed on the side surface of the multi-layer substrate.

The second connecting wires may be formed in the multi-layer substratesuch that they are partially exposed on the side surface of themulti-layer substrate. In a step-down DC-DC converter, for instance, thedensity of mounting devices can be increased while preventing parasiticinductance from deteriorating the characteristics of the DC-DCconverter, when the second connecting wires between the input terminaland the semiconductor integrated circuit device, the second connectingwires connected to the negative feedback terminal of the semiconductorintegrated circuit device, etc. are exposed on the side surface toprovide low inductance, while part of the second connecting wirescausing no problems in characteristics even with series-connectedparasitic inductance are formed in the multi-layer substrate.

The multi-layer, insulating substrate preferably has a square shapehaving four side surfaces, all of which have the second externalterminals connected to the ground. Such structure makes it possible toprevent a magnetic flux from leaking from the side surface of themulti-layer substrate.

The first connecting wires may have width expanding toward the secondconnecting wires. With such structure, heat generated by thesemiconductor integrated circuit device is dissipated to the circuitboard through the first connecting wires and the second externalterminals connected thereto.

The multi-layer substrate preferably has a magnetic gap for preventing amagnetic flux flow and improving the DC superimposing characteristics ofthe laminated coil, at least in a region inside the laminated coil.

The multi-layer substrate preferably comprises a region having thelaminated coil, and upper and lower insulating layer regions above andbelow it. Conductor lines for the laminated coil are not formed in theupper and lower insulating layer regions. With a magnetic gap disposedinside the laminated coil at least in an upper or lower insulating layerregion, a magnetic flux is prevented from flowing outward, therebyreducing the leakage of a magnetic flux. The magnetic gap may be aspace, or filled with a non-magnetic material, a dielectric material, ora magnetic material having lower permeability than that of the magneticmaterial forming the multi-layer substrate.

According to another preferred embodiment of the present invention, theupper insulating layer region has a magnetic shield formed by aconductor pattern to reduce the leakage of a magnetic flux. The magneticshield is preferably formed on the multi-layer substrate surface, or inan upper or lower insulating layer region, which is inside the laminatedcoil. According to a further preferred embodiment of the presentinvention, at least the first main surface of the multi-layer substratehas recess in a region inside the laminated coil.

The semiconductor integrated circuit device is mounted on a regioninside the laminated coil. The semiconductor integrated circuit devicemay be in the form of a bare chip or a package. The semiconductorintegrated circuit device is preferably connected to the multi-layersubstrate by wire-bonding or flip chips.

At least the first main surface of the multi-layer substrate ispreferably covered with an insulating layer of a overcoat glass, adielectric material, or a low-permeability magnetic material. The firstconnecting wires may be formed on or between the insulating layers.

The first main surface of the multi-layer substrate is preferablycovered with a resin layer or a metal case connected to the groundedfirst connecting wires. Such structure makes it easy to handle devicesby a mounter, thereby protecting the mounted devices and reducing theinfluence of external noise.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view showing a DC-DC converter according to oneembodiment of the present invention.

FIG. 2 is a perspective view showing a multi-layer, insulating substrateused in a DC-DC converter according to one embodiment of the presentinvention.

FIG. 3 is a cross-sectional view showing the internal structure of amulti-layer, insulating substrate used in a DC-DC converter according toone embodiment of the present invention.

FIG. 4 is a cross-sectional view showing a magnetic flux flow generatedby a laminated coil formed in a multi-layer, insulating substrate usedin a DC-DC converter according to one embodiment of the presentinvention.

FIG. 5 is an exploded perspective view showing a multi-layer, insulatingsubstrate used in a DC-DC converter according to one embodiment of thepresent invention.

FIG. 6 is a cross-sectional view showing the internal structure of amulti-layer, insulating substrate used in a DC-DC converter according toanother embodiment of the present invention.

FIG. 7 is a cross-sectional view showing the internal structure of amulti-layer, insulating substrate used in a DC-DC converter according toa further embodiment of the present invention.

FIG. 8 is a cross-sectional view showing the internal structure of amulti-layer, insulating substrate used in a DC-DC converter according toa still further embodiment of the present invention.

FIG. 9 is a cross-sectional view showing the internal structure of amulti-layer, insulating substrate used in a DC-DC converter according toa still further embodiment of the present invention.

FIG. 10 is a cross-sectional view showing the internal structure of amulti-layer, insulating substrate used in a DC-DC converter according toa still further embodiment of the present invention.

FIG. 11 is a cross-sectional view showing the internal structure of amulti-layer, insulating substrate used in a DC-DC converter according toa still further embodiment of the present invention.

FIG. 12 is a perspective view showing a multi-layer, insulatingsubstrate used in a DC-DC converter according to a still furtherembodiment of the present invention.

FIG. 13 is a perspective view showing a multi-layer, insulatingsubstrate used in a DC-DC converter according to a still furtherembodiment of the present invention.

FIG. 14 is a partially exploded perspective view showing a multi-layer,insulating substrate used in a DC-DC converter according to a stillfurther embodiment of the present invention.

FIG. 15 is a cross-sectional view showing a magnetic flux flow generatedby a laminated coil formed in a multi-layer, insulating substrate usedin a DC-DC converter according to a still further embodiment of thepresent invention.

FIG. 16 is a perspective view showing a multi-layer, insulatingsubstrate used in a DC-DC converter according to a still furtherembodiment of the present invention.

FIG. 17 is an enlarged perspective view showing part of the multi-layer,insulating substrate of FIG. 16.

FIG. 18 is a partially exploded perspective view showing a multi-layer,insulating substrate used in a DC-DC converter according to a stillfurther embodiment of the present invention.

FIG. 19 is a cross-sectional view showing a magnetic flux flow generatedby a laminated coil formed in a multi-layer, insulating substrate usedin a DC-DC converter according to a still further embodiment of thepresent invention.

FIG. 20 is a perspective view showing a DC-DC converter according to astill further embodiment of the present invention.

FIG. 21 is a perspective view showing a multi-layer, insulatingsubstrate used in a DC-DC converter according to a still furtherembodiment of the present invention.

FIG. 22 is a perspective view showing a DC-DC converter according to astill further embodiment of the present invention.

FIG. 23 is a partially exploded perspective view showing a multi-layer,insulating substrate used in a DC-DC converter according to a stillfurther embodiment of the present invention.

FIG. 24 is a view showing a DC-DC converter according to a furtherembodiment of the present invention.

FIG. 25 is a perspective view showing a multi-layer, insulatingsubstrate used in a DC-DC converter according to a still furtherembodiment of the present invention.

FIG. 26 is a view showing one example of the DC-DC converter circuit.

FIG. 27 is a view showing another example of the DC-DC convertercircuit.

FIG. 28 is a view showing a further example of the DC-DC convertercircuit.

FIG. 29 is a view showing a still further example of the DC-DC convertercircuit.

FIG. 30 is a perspective view showing a conventional DC-DC converter.

FIG. 31 is a perspective view showing another conventional DC-DCconverter.

FIG. 32 is a cross-sectional view showing a magnetic flux leaking from alaminated inductor formed in a multi-layer substrate.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

FIG. 1 shows a DC-DC converter according to one embodiment of thepresent invention, FIG. 2 shows a multi-layer substrate used in theDC-DC converter, FIG. 3 shows the internal structure of the multi-layersubstrate, FIG. 4 shows a magnetic flux flow generated by a laminatedcoil formed in the multi-layer substrate, and FIG. 5 shows the layerstructure of the multi-layer substrate. This DC-DC converter has thesame equivalent circuit as that of the step-down DC-DC converter shownin FIG. 26.

The multi-layer substrate 10 is formed by laminating magnetic insulatinglayers each having a coil pattern, and has opposing first and secondmain surfaces and side surfaces connecting them. The first main surfaceis provided with first external terminals 50 a-50 h for mounting asemiconductor integrated circuit device IC, first external terminals 65a-65 d for mounting capacitance elements, and first connecting wires 60a-60 g, 70 a, 70 b. The second main surface is provided with secondexternal terminals 90 (Vcon, Ven, Vdd, Vin, Vout, GND) connected to aprinted circuit board. In this embodiment, the second external terminals90 have a land grid array (LGA)-type terminal structure.

A metal case (not shown) connected to the first connecting wires 70 a,70 b may be disposed to cover the semiconductor integrated circuitdevice IC and the capacitance elements mounted on the first mainsurface. The metal case may be formed by a thin plate made of steel suchas stainless steel, which is formed into a cap shape having a ceilingand opposing sidewalls, and part of the walls may have such openings nothindering mounting stability. The metal case is provided with aconductive plating of Ni, Sn, etc. The connection of the metal casewalls to the first connecting wires 70 a, 70 b by a solder or aconductive adhesive can shield noise and protect the mounted devices.

The magnetic insulating layer is made of a sintered magnetic materialsuch as soft ferrite, or a magnetic powder-resin composite in whichmagnetic powder of soft ferrite, amorphous or micro-crystallinesoft-magnetic alloys, etc. is dispersed in a resin. The soft ferrite ispreferably spinel ferrite of Ni—Cu, Ni—Zn, Ni—Cu—Zn, Mg—Zn or Li—Znhaving resistivity of 1×10³ Ω·cm or more, or hexagonal ferrite havingexcellent high-frequency characteristics.

The multi-layer substrate 10 made of soft ferrite is preferably formedby an LTCC (low-temperature co-fired ceramics) method and a printingmethod. For instance, a soft ferrite paste is formed into green sheetsby a doctor blade method, a calendar roll method, etc., and a conductivepaste of Ag, Cu or their alloys is printed or coated in a predeterminedpattern on each green sheet. These green sheets are laminated, andsintered at a desired temperature of 1100° C. or lower depending on theconductive paste and the ferrite.

The multi-layer substrate 10 made of a magnetic powder-resin compositeis obtained by forming via-holes in each sheet of the magneticpowder-resin composite, and forming a thin metal layer of Cu, etc. onthe sheet by a plating method, etc. The multi-layer substrate 10 is thencoated with a photoresist, subjected to patterning exposure to light toremove a photoresist layer from other regions than the wiring and thevia-holes, and then chemically etched to remove the thin metal layer.Thus, a magnetic powder-resin composite sheet having the desired coilpattern having via-holes can be obtained. Pluralities of the magneticpowder-resin composite sheets each having a coil pattern are laminated,and pressure-bonded while heating to provide a multi-layer substrate 10.

The coil patterns are connected through means such as via-holes (shownby black circles in the figure), etc. to form a laminated coil(inductor). Among pluralities of insulating layers S1-S13 in themulti-layer substrate 10, the insulating layers S3-S12 have coilpatterns. The insulating layers S3-S12 are laminated with upper andlower insulating layers S1, S2, S13, with the ends of the coil patternssuccessively connected through via-holes Lg3-Lg11. The insulating layersS3-S12 constitute a region having the laminated coil, the insulatinglayers 51, S2 constitute the upper insulating layer region, and theinsulating layers S12, S13 constitute the lower insulating layer region.

One end of the laminated coil reaches the first main surface throughvia-holes Lg1, Lg2 and is connected to the first external terminal 50 h.The other end of the laminated coil reaches the second main surfacethrough via-holes V12 o, V13 o, and is connected to the second externalterminal Vout, and further connected to an IC-mounting, first externalterminal 50 e (connected to a negative feedback terminal of thesemiconductor integrated circuit device) and a capacitor-mounting, firstexternal terminal 65 a through via-holes V1 o-V11 o and the firstconnecting wire 60 e.

The second external terminals 90 are named after the connectingterminals Vcon, Ven, Vdd, Vin, Vout and GND of the semiconductorintegrated circuit device IC. The second external terminal 90 (Vcon) isconnected to an output-voltage-variably-controlling terminal (secondcontrol terminal) Vcon of the semiconductor integrated circuit deviceIC. The second external terminal 90 (Ven) is connected to an outputON/OFF-controlling terminal Ven of the semiconductor integrated circuitdevice IC. The second external terminal 90 (Vdd) is connected to aterminal (first control terminal) Vdd for ON/OFF-controlling theswitching devices in the semiconductor integrated circuit device IC. Thesecond external terminal 90 (Vin) is connected to an input terminal Vinof the semiconductor integrated circuit device IC. The second externalterminal Vout is connected to an output terminal Vout of thesemiconductor integrated circuit device IC. The second external terminal90 (GND) is connected to a ground terminal GND of the semiconductorintegrated circuit device IC.

Each layer is provided with pluralities of via-holes V1 a-V13 p in aregion outside the coil pattern. The via-holes on the insulating layersare connected in the thickness direction of the multi-layer substrate(along a magnetic field generated by the laminated coil), therebyforming the second connecting wires 80 for connecting the firstconnecting terminals 50 a-50 h to the second connecting terminals 90.

In this embodiment, pluralities of second connecting wires 80 extendaround all four sides of the laminated coil, and are connected to thesecond external terminal 90 (GND), exhibiting a magnetic shield effectthat prevents a magnetic flux from leaking from the side surfaces of themulti-layer substrate 10.

The upper surface of the multi-layer substrate 10 is provided with thesemiconductor integrated circuit device IC in a substantially centerportion, and input and output capacitors Cin, Cout therearound. Althoughthe arrangement of the first external terminals 50 a-50 h is determinedby the positions of the terminals of the semiconductor integratedcircuit device IC, they are preferably positioned inside the laminatedcoil pattern when the multi-layer substrate 10 is viewed from the firstmain surface side. The first connecting wires 60 a-60 g radially extendfrom the first external terminals 50 a-50 g to the side surface suchthat they are as short as possible, and connected to via-holes V1 d-V1g, V1 m-V1 o. Even when a magnetic flux leaks from the laminated coil tothe first main surface, such structure reduces the magnetic fluxcrossing the first connecting wires, thereby lowering noise.

The second main surface of the multi-layer substrate 10 is provided withthe second external terminal 90 (GND) in a wide region including thecenter portion. A magnetic shield effect provided by the second externalterminal 90 (GND) and other second external terminals 90 reduces amagnetic flux leaking to the second main surface. The second externalterminal 90 (GND) is connected to a circuit board by soldering, therebypermitting heat generated by the semiconductor integrated circuit deviceIC to escape to the circuit board effectively.

In this embodiment, the multi-layer substrate 10 has a magnetic gap GP1in the upper insulating layer region. The magnetic gap GP1 is a space,which is vacant or filled with a non-magnetic material, a dielectricmaterial or a low-permeability magnetic material. The space may beprovided by a sheet-punching method, a method of forming a portioncorresponding to the space with a combustible carbon paste or a resinand burning it, etc. Alternatively, the magnetic gap may be formed froma paste of a non-magnetic material, a dielectric material or alow-permeability magnetic material, which is printed or formed into asheet. Materials for forming the magnetic gap GP1 include various typesof glass such as B₂O₃—SiO₂ glass and Al₂O₃—SiO₂ glass, Zn ferrite, ZrO₂,Li₂O—Al₂O₃-4SiO₂, Li₂O—Al₂O₃-2SiO₂, ZrSiO₄, CaZrO₃, SiO₂, TiO₂, WO₃,Ta₂O₅, Nb₂O₅, etc.

The magnetic gap GP1 provides large magnetic resistance, so that amagnetic flux φ flows predominantly from a region inside the laminatedcoil to a region outside the laminated coil, resulting in a reducedamount of a magnetic flux φ leaking to the first main surface. Themagnetic flux passing through the magnetic gap GP1 flows through theregion outside the laminated coil, resulting in a remarkably reducedamount of a leaked magnetic flux than when there is no magnetic gap GP1.

The width of the magnetic gap GP1 is 5 μm or more, preferably 20 μm ormore. The magnetic gap GP1 is preferably formed in a region including acenterline of the laminated coil, whose area is ½ or more of that of theregion inside the laminated coil. As shown in FIG. 6, a magnetic gap GP1may be provided substantially in the entire area of the multi-layersubstrate 10.

As shown in FIGS. 7 and 8, the magnetic gap GP1 may be provided in aregion having the laminated coil. FIG. 7 shows a magnetic gap GP1provided in a region inside the laminated coil, and FIG. 8 shows amagnetic gap GP1 provided in an entire horizontal area (including aregion inside the laminated coil) in the multi-layer substrate 10. Inthese cases, the laminated coil has stable DC superimposingcharacteristics.

As shown in FIGS. 9 and 10, the magnetic gap GP1 may be constituted bypluralities of magnetic gaps arranged in one or more planes. FIG. 9shows magnetic gaps arranged in regions inside and outside the laminatedcoil, and FIG. 10 shows pluralities of magnetic gaps GP1 arranged in aregion inside the laminated coil at different positions in a laminationdirection. When pluralities of laminated coils are formed in themulti-layer substrate as shown in FIG. 11, a magnetic gap GP1 or amagnetic shield SG1 may be disposed inside the laminated coils.

FIG. 12 shows a multi-layer substrate used in a DC-DC converteraccording to a still further embodiment of the present invention. Secondconnecting wires 80 connected to second external terminals 90 areelectrode strips formed on four side surfaces of the multi-layersubstrate. The second connecting wires 80 may be formed by exposedvia-holes, or the printing, transferring, etc. of a conductive paste.Because the other structure is the same as in the above embodiment, itsexplanation will be omitted. The formation of the second connectingwires 80 on the multi-layer substrate surfaces reduces parasiticinductance. This DC-DC converter module also has excellent voltageconversion efficiency despite its small size.

FIG. 13 shows a multi-layer substrate used in a DC-DC converter moduleaccording to a still further embodiment of the present invention. Secondconnecting wires 80 connected to second external terminals 90 may beformed by via-holes, which are exposed on four side surfaces of themulti-layer substrate from steps to a second main surface. Becausevia-holes exposed on the side surfaces can be soldered, they can bestrongly connected to a printed circuit board with reduced parasiticinductance. Although each side surface has a step in this embodiment,the step may be formed only on a side surface having lines whoseseries-connected parasitic inductance would be harmful tocharacteristics.

Another feature of this embodiment is that the multi-layer substrate 10has a magnetic shield SG1 formed by a conductor pattern in an upperinsulating layer region. FIG. 14 shows part of layers in the multi-layersubstrate, and FIG. 15 shows a magnetic flux flow. The magnetic shieldSG1 is formed by printing a conductive paste like each coil pattern. Asshown in FIG. 15, a magnetic flux does not flow outward from themagnetic shield SG1, suppressing the leakage of a magnetic flux.Although the magnetic shield is formed only in a region inside thelaminated coil in this embodiment, it may cover a wide region except forthe via-holes. The DC-DC converter comprising such a multi-layersubstrate also has excellent voltage conversion efficiency despite itssmall size.

FIG. 16 shows a multi-layer substrate used in a DC-DC converteraccording to a still further embodiment of the present invention.Although second connecting wires 80 connected to second connectingterminals 90 are formed by via-holes, the multi-layer substrate isprovided with castellation on four side surfaces between first andsecond main surfaces, so that the via-holes are exposed in the recessesof the castellation. FIG. 17 is an enlarged view showing a portion A inthe multi-layer substrate of FIG. 16. Because ribbon-shaped via-holesare exposed in the bottoms of the recesses or grooves on the sidesurfaces of the multi-layer substrate, soldering can be conducted in awider area than in the multi-layer substrate of FIG. 13, resulting instronger connection to a circuit board. Also, the parasitic inductancecan be reduced substantially to the same level as in FIG. 12.

Another feature of this embodiment is that the multi-layer substrate hasrecesses on the first and second main surfaces each in a region insidethe laminated coil. FIG. 18 shows part of layers constituting themulti-layer substrate, and FIG. 19 shows a magnetic flux flow. Recessesho1, ho2 are provided by through-holes of insulating layers in themulti-layer substrate. Although a magnetic flux φ flows from a regioninside the laminated coil to a region outside the laminated coil throughupper and lower insulating layer regions, the recesses ho1, ho2 act asmagnetic gaps as shown in FIG. 19, thereby suppressing the magnetic fluxfrom exiting from the insulating layer. Although a recess is formed oneach of the first and second main surfaces in the depicted example, itmay be formed at least on a main surface on which a semiconductorintegrated circuit device is mounted. The DC-DC converter comprisingsuch a multi-layer substrate also has excellent voltage conversionefficiency despite its small size.

FIG. 20 shows a DC-DC converter according to a still further embodimentof the present invention, and FIG. 21 shows a multi-layer substrate usedin the DC-DC converter. The DC-DC converter in this embodiment is amulti-phase type having two laminated coils in the multi-layersubstrate. This multi-phase DC-DC converter has the same circuitstructure as shown in FIG. 29. Two laminated coils (not shown) arearranged side by side in the multi-layer substrate. A semiconductorintegrated circuit device IC mounted on a laminate substrate comprises acontrol circuit CC operating switching circuits in parallel. Like above,second external terminals 90 formed on the multi-layer substrate bearthe names of terminals Vcon, Ven, Vdd, Vin, Vout and GND of thesemiconductor integrated circuit device IC, to which the second externalterminals 90 are connected. Because the DC-DC converter in thisembodiment is substantially the same as in the above embodiments exceptthat the second external terminal Vout is connected to the firstexternal terminals 50 h 1, 50 h 2 via two laminated coils (not shown),its explanation will be omitted. The DC-DC converter having such amulti-layer substrate also has excellent conversion efficiency despiteits small size.

FIG. 22 shows a DC-DC converter according to a still further embodimentof the present invention, FIG. 23 shows a multi-layer substrate used inthe DC-DC converter, and FIG. 24 shows a DC-DC converter circuit. Inthis embodiment, part of first connecting wires are getting wider towardsecond connecting wires. The second connecting wires are formed bypluralities of via-holes to connect the first connecting wires to secondexternal electrodes. Such structure reduces parasitic inductance, andefficiently dissipates heat generated by a semiconductor integratedcircuit device. In this embodiment, a first external terminal 50 hconnected to one end of a laminated coil is connected to a secondexternal terminal NC via a first connecting wire 60 z, to facilitate theinductance measurement of the laminated coil. The second externalterminal NC is not connected to a connecting line formed on a circuitboard.

The size reduction of a multi-layer substrate likely permits noise fromswitch circuits to enter a control signal path via a ground, causingmalfunction. To overcome this problem, a ground (for a power system)connected to a switching device SW2 and a ground (for a source system)of the control signal path are separated from each other, and connectedto different second external terminals PGND, SGND in this embodiment.The DC-DC converter in this embodiment has excellent conversionefficiency despite its small size.

Insulating layers produced by an LTCC method, etc. are preferably madeof soft ferrite having a Curie temperature of 100° C. or higher. Thecomposition of such soft ferrite may be properly selected depending onthe magnetic properties (initial permeability, loss, qualitycoefficient, etc.) required for inductors. It preferably comprises maincomponents comprising 40-50 mol % of Fe₂O₃, 20-40 mol % of NiO, 10-20mol % of CuO, 2-20 mol % of ZnO, and 0.3-7 mol % of CO₃O₄, and 4% bymass or less of Bi₂O₃ based on the total amount of the main components,meeting the conditions of 1≦NiO/CuO≦4, 0.5≦CuO/ZnO≦10, and 1≦NiO/ZnO≦20by a molar ratio. This soft ferrite is sinterable at 950° C. or lower,having a Curie temperature Tc of 120° C. or higher and initialpermeability (frequency: 100 kHz) of 10 or more. Also, its complexpermeability has a real part of 10 or more and an imaginary part of lessthan 5 in a frequency range of 1-200 MHz.

Such soft ferrite is blended with a binder, a plasticizer, a solvent,etc. to form a slurry, which is formed into green sheets by a doctorblade method. After bored by a laser, each sheet is screen-printed witha conductive paste (for instance, Ag: 100%) to form a coil pattern, afirst external terminal pattern, a first connecting wire pattern,via-holes for second connecting wires, a second external terminalpattern, etc.

Ferrite used for the magnetic gap GP1 preferably has a Curie temperatureTc of −40° C. or lower. Because the Curie temperature Tc variesdepending on the amounts of Fe₂O₃ and ZnO, main components of theferrite, the amounts of Fe₂O₃ and ZnO are determined such that the Curietemperature becomes −40° C. or lower, taking into consideration matchingin sintering shrinkage with ferrite for forming the insulating layer.Such ferrite for the magnetic gap GP1 includes Cu—Zn ferrite comprising40-55 mol % of Fe₂O₃, and 40 mol % or more of ZnO, the balance beingCuO, as main components, which has a Curie temperature of lower than−40° C., with no magnetism at room temperature. The printing of a pasteof such ferrite provides the magnetic gap GP1.

The present invention will be explained in more detail with reference toExamples below without intention of restricting the scope of the presentinvention.

EXAMPLE 1 COMPARATIVE EXAMPLE 1

Production of DC-DC Converter having Structure Shown in FIGS. 1-5

Ferrite having a Curie temperature Tc of 140° C. and initialpermeability of 25 at a frequency of 100 kHz, which comprised maincomponents comprising 47.0 mol % of Fe₂O₃, 36.7 mol % of NiO, 11.0 mol %of CuO, 5.0 mol % of ZnO and 0.3 mol % of CO₃O₄, and 1.0% by mass ofBi₂O₃ per the total amount of the main components, was formed intosheets by an LTCC method, and each sheet was provided with apredetermined coil pattern by an Ag paste. Insulating layers werelaminated such that a magnetic gap GP1 made of Cu—Zn ferrite (Curietemperature: −60° C.) comprising main components comprising 45.7 mol %of Fe₂O₃ and 4.0 mol % of ZnO, the balance being CuO, and 0.3% by massof Bi₂O₃ per the total amount of the main components was formed on aninsulating layer S2, pressure-bonded, and sintered to produce a motherboard in which pluralities of multi-layer substrates each having alaminated coil having inductance of 3.3 μH were connected. Afterdegreasing, the sintering was conducted in an electric furnace with anair atmosphere, with temperature elevation at 150° C./hr, keeping at900° C. for 1 hour, and then temperature decrease at about 300° C./hr.

Conductor patterns formed by electric plating on an outer surface of themother board were subjected to Ni—P plating and Au plating to form firstexternal terminals. Connected to the first external terminals were asemiconductor-integrated circuit device IC, and capacitors Cin (10 μF),Cout (4.7 μF) by soldering. With a device-mounting surface sealed by anepoxy resin, the mother board was divided along dividing grooves givenin advance, to obtain DC-DC converters of 4.5 mm×3.2 mm×1.4 mm.

When the multi-layer substrate was viewed from above, a region insidethe laminated coil had an area of 4.2 mm², and a region outside theregion had an area of 4.3 mm² A portion with the laminated coil was asthick as 0.3 mm, with an upper insulating layer region and a lowerinsulating layer region each having a thickness of 0.2 mm. The magneticgap was 20 μm with an area of 2.1 mm². When the resultant DC-DCconverter was operated to provide an output voltage Vo of 3.2 V from aninput voltage V1 of 3.6 V, a voltage conversion efficiency of more than95% was obtained when an output current Io was 150 mA.

A coil inductor (inductance: 3.3 μH) having a drum ferrite core wasmounted on a printed circuit board together with the same semiconductorintegrated circuit device IC and capacitors Cin, Cout as in Example 1,to produce a DC-DC converter of Comparative Example 1. Measurement underthe same conditions as in Example 1 revealed that the DC-DC converter ofComparative Example 1 had substantially comparable voltage conversionefficiency of more than 95%.

However, the DC-DC converter of Example 1 comprising capacitanceelements suffered little influence of parasitic inductance generated bythe first and second connecting wires, etc., while exhibiting comparablevoltage conversion efficiency to that of Comparative Example 1. Theparasitic inductance in the DC-DC converter of Example 1 was less thanabout one-fifth in the DC-DC converter of Comparative Example 1. Such aterminal structure as LGA, etc. suppressing a magnetic flux from leakingfrom the inductor enabled the high-density mounting of other circuitelements near the DC-DC converter on the printed circuit board.

Although the DC-DC converter of the present invention has been explainedabove referring to the attached drawings, the present invention is notrestricted to the depicted embodiments, but may be modified variouslywithin the scope of the present invention. As shown in FIG. 25, forinstance, the first main surface of the multi-layer substrate may becovered with an overcoat, and the first connecting wires may be formedon a layer near the first main surface in the multi-layer substrate.With such a structure, the elongation of the plating andshort-circuiting by an excess solder can be prevented, even if the firstconnecting wires on the first main surface have narrow gaps. Also evenlarge first external terminals would not interfere with the firstconnecting wires.

The use of the same insulating material as the multi-layer substrate forthe overcoat is not preferable because it increases parasiticinductance. Thus, the overcoat is made of non-magnetic materials such asglass and dielectric materials, or low-permeability magnetic materials.The formation of the first external terminals and the first connectingwires on the overcoat is preferable because parasitic inductancegenerated by the first connecting wires can be further reduced.

Effect of the Invention

While being small, the DC-DC converter of the present inventionintegrally comprising a semiconductor integrated circuit IC and aninductor is excellent in the reduction of a magnetic flux leaking fromthe multi-layer substrate, the reduction of parasitic inductance, theheat dissipation of the semiconductor integrated circuit IC, etc.

1. A DC-DC converter comprising a soft-magnetic, multi-layer substrateprovided with a laminated coil constituted by connecting pluralities ofconductor lines, and a semiconductor integrated circuit devicecomprising a switching device and a control circuit, which are mountedon said soft-magnetic, multi-layer substrate, said semiconductorintegrated circuit device comprising an input terminal, an outputterminal, a first control terminal for controlling the ON/OFF of saidswitching device, a second control terminal for variably controllingoutput voltage, and ground terminals; said soft-magnetic, multi-layersubstrate comprising first external terminals formed on a first mainsurface, second external terminals formed on a second main surface, andconnecting wires connecting said first external terminals and saidsecond external terminals; terminals of said semiconductor integratedcircuit device being connected to said first external terminals on saidsoft-magnetic, multi-layer substrate; at least part of said firstexternal terminals being electrically connected to said second externalterminals through said connecting wires; and said output terminal ofsaid semiconductor integrated circuit device being connected to saidsecond external terminal via said laminated coil, and being connected toother said second external terminal via said connecting wires.
 2. TheDC-DC converter according to claim 1, wherein said connecting wires areformed by electrodes on the surface of said soft-magnetic, multi-layersubstrate and/or in said soft-magnetic, multi-layer substrate.
 3. TheDC-DC converter according to claim 1, wherein said semiconductorintegrated circuit device has a negative feedback terminal, and whereinsaid first external terminal connected to said negative feedbackterminal is connected to the other end of the laminated coil connectedto said output terminal.
 4. The DC-DC converter according to claim 1,wherein capacitance elements are connected to said first externalterminals formed on the first main surface of said multi-layersubstrate, and wherein said input and/or output terminals of saidsemiconductor integrated circuit device are connected to the groundterminals via said capacitance elements.
 5. A DC-DC converter comprisinga soft-magnetic, multi-layer substrate provided with a laminated coilconstituted by connecting pluralities of conductor lines, and asemiconductor integrated circuit device comprising a switching deviceand a control circuit, which are mounted on said soft-magnetic,multi-layer substrate, said semiconductor integrated circuit devicecomprising an input terminal, an output terminal, a first controlterminal for controlling the ON/OFF of said switching device, a secondcontrol terminal for variably controlling output voltage, a groundconnected to said switching device, and a ground of the control signalpath; said soft-magnetic, multi-layer substrate comprising firstexternal terminals formed on a first main surface, second externalterminals formed on a second main surface, and connecting wiresconnecting said first external terminals and said second externalterminals; terminals of said semiconductor integrated circuit devicebeing connected to said first external terminals on said soft-magnetic,multi-layer substrate; at least part of said first external terminalsbeing electrically connected to said second external terminals throughsaid connecting wires; said input or output terminal of saidsemiconductor integrated circuit device being connected to said secondexternal terminals via said laminated coil; and said ground connected tosaid switching device and said ground of the control signal path beingconnected to different second external terminals.
 6. The DC-DC converteraccording to claim 2, wherein said connecting wires are formed byelectrodes on the surface of said soft-magnetic, multi-layer substrateand/or in said soft-magnetic, multi-layer substrate.
 7. The DC-DCconverter according to claim 2, wherein said semiconductor integratedcircuit device has a negative feedback terminal, and wherein said firstexternal terminal connected to said negative feedback terminal isconnected to the other end of the laminated coil connected to saidoutput terminal.
 8. The DC-DC converter according to claim 2, whereincapacitance elements are connected to said first external terminalsformed on the first main surface of said multi-layer substrate, andwherein said input and/or output terminals of said semiconductorintegrated circuit device are connected to the ground terminals via saidcapacitance elements.